Refrigeration system and heat pump arrangement for heating and cooling battery-operated vehicles and method of operating the same

Abstract

The invention relates to a refrigeration system and heat pump arrangement for heating and cooling battery-operated vehicles, having a refrigerant circuit with a compressor (1), a heating condenser (2) or a water-cooled condenser (18), a second 3 / 2-way refrigerant valve with expansion function (3), an ambient heat exchanger (4), at least one evaporator (6) with an associated refrigerant valve with expansion function (5) as well as a refrigerant path arranged parallel to the evaporator (6) via a chiller (9) with an upstream refrigerant valve with expansion function (10), wherein an internal heat exchanger (13), a refrigerant collector (11) as well as the evaporator (6) an the chiller (9) are connected to one another in different arrangements. * Fig. 1

Description

REFRIGERATION SYSTEM AND HEAT PUMP ARRANGEMENT FOR HEATING AND COOLING BATTERY-OPERATED VEHICLES AND METHOD OF OPERATING THE SAME

[0001] The invention relates to a refrigeration system and heat pump arrangement for heating and cooling battery-operated vehicles.

[0002] The invention further relates to methods for operating the refrigeration and heat pump arrangement in selected operating modes, wherein the refrigerant circuit comprises the cooling or the heating of the cabin depending on the mode and thus represents a combined heat pump and refrigeration system.

[0003] The field of application of the invention is in the field of electrically driven vehicles which, as an energy store, generally use high-voltage batteries (HV batteries) for the energy supply of the drive train of the vehicle.

[0004] Further fields of application of the invention are in vehicles with so-called plug-in hybrids which produce only small amounts of waste heat and whose batteries are integrated into a heat management system.

[0005] An efficient heat supply of the vehicle in combination with an optimal heat management of the battery and the electric drive train plays an important role.

[0006] Electric battery-operated vehicles generate relatively little waste heat and thus, in such vehicles, there is a regular need to generate heat efficiently for heating the vehicle cabin and to make it available in a sufficient amount and at an appropriate temperature level.

[0007] Heat management systems for battery electric vehicles must allow for flexible operation within a wide range of operating conditions. The operation of the vehicle and thus of the heat management system is influenced by different factors, such as ambient and driving conditions, human comfort and the component operation, for example of the high-voltage battery (HV battery), the electric drive train and the control devices.

[0008] With regard to these aspects, the heat management of a vehicle must enable comfort functions, such as interior air-conditioning, within a desired temperature range and at the same time guarantee safe operation of the vehicle. In particular, the removal of fittings or de-icing of the windscreen and the cooling of the HV battery at high ambient temperatures must be realised to a sufficient extent.

[0009] Modern heat management systems for battery electric vehicles allow for the incorporation of different heat sources and heat sinks, both via the refrigerant circuit and via the coolant circuit, in order to enable efficient and dynamic operation of the heating and cooling system and to ensure situation-dependent thermal performance for cooling or heating for different applications.

[0010] In the prior art, refrigerant circuits for refrigeration and heat pump circuits are known for this constellation, which are specially tailored to battery-operated vehicles.

[0011] For example, DE 10 2019 109 796 A1 reveals a heat flow management device and a method for operating a heat flow management device which has a refrigerant circuit and a drive train coolant circuit as well as a heating train heat transfer medium circuit.

[0012] DE 10 2016 100 971 A1 relates to a climate control system for a vehicle with a heat pump subsystem and DE 10 2008 062 176 A1 discloses a mechanism and a method for tempering electrical elements of a motor vehicle.

[0013] US 2019 / 0344640 A1 discloses a heat management device for a vehicle which comprises a heat pump.

[0014] DE 10 2020 111 505 A1 relates to a heat pump arrangement for battery-operated vehicles and a method for operating a heat pump arrangement, wherein the utilisation of the waste heat of the vehicle requires multiple chillers to couple the refrigerant circuit and the heat transfer medium circuit.

[0015] Furthermore, a vehicle air-conditioner is known from JP 2019- 206 215 A. A vehicle air-conditioner is provided in which, in the event that a respective desired cooling temperature differs from several cooled devices, the respective desired cooling temperature can be achieved in a simple manner. It comprises a first heat transfer medium circuit, in which a first heat transfer medium flows, which absorbs heat emitted by a battery, a second heat transfer medium circuit, in which a second heat transfer medium flows, which absorbs the heat emitted by an electric motor, a first heat transfer medium heat exchanger, which, by means of a heat exchange between a refrigerant flowing in a refrigerant circuit and the first heat transfer medium flowing in the first heat transfer medium circuit, has the effect that heat is emitted from the first heat transfer medium to the refrigerant, and a second heat transfer medium heat exchanger, which is connected on a side of the first heat transfer medium heat exchanger downstream in the refrigerant flow direction in the refrigerant circuit and, by means of a heat exchange between the refrigerant flowing in the refrigerant circuit and the second heat transfer medium flowing in the second heat transfer medium circuit, has the effect that heat is transferred from the second heat transfer medium to the first heat transfer medium.

[0016] Also, JP 2019-182 135 A reveals a cooling system and JP 2013- 189 118 A reveals a further vehicle air-conditioner system.

[0017] However, these systems are often very complex and only rarely able to combine the needs and requirements of the vehicle occupants for an adequate heat supply via the air-conditioner of the vehicle, which is also referred to as air-conditioning device, with the cooling or also heating of the battery and the electric drive train which is optimally required in the various operating states.

[0018] The heat management system according to DE 10 2021 131 215 has a system architecture which enables flexible, high-performance and efficient operation, while also reducing the number of components.

[0019] However, here too there are certain disadvantages. For example, there is a high pressure drop on the refrigerant side in high-load, cooling or heating operation and a relatively low heating performance at very low ambient temperatures, so that an additional air heater must be used. Furthermore, there is a high risk of chattering noises at the evaporator during reheat operation, which is perceived in part as disturbing by the vehicle occupants, and de-icing or defrosting of the ambient heat exchanger is possible only under certain circumstances.

[0020] It is an object of the invention to indicate refrigeration system and heat pump circuits which achieve a high cooling and heating performance in an efficient manner and thus considerably reduce the total energy consumption for heating and cooling, which leads to a higher range of electric vehicles.

[0021] The object of the invention is achieved with a refrigeration system and heat pump arrangement for heating and cooling battery-operated vehicles and methods with the features of the independent claims. Further developments are indicated in the dependent claims.

[0022] The object of the invention is in particular achieved with a refrigeration system and heat pump arrangement for heating and cooling battery-operated vehicles which has a refrigerant circuit:

[0023] - with a compressor, a heating condenser according to layout A or a water-cooled condenser according to layout B, a second 3 / 2-way refrigerant valve with expansion function, an ambient heat exchanger, at least one evaporator with an associated refrigerant valve with expansion function as well as a refrigerant path arranged parallel to the evaporator via a chiller with an upstream refrigerant valve with expansion function, wherein

[0024] - the high-pressure side of the compressor is connected to the heating condenser or the water-cooled condenser and to a valve inlet of a first 3 / 2-way refrigerant valve with expansion function and a second valve outlet of the first 3 / 2-way refrigerant valve with expansion function is connected to a refrigerant collector as well as a first valve outlet of the first 3 / 2-way refrigerant valve with expansion function is connected to the ambient heat exchanger, and

[0025] - a bypass line which can be shut with a shut-off valve is arranged to the first 3 / 2-way refrigerant valve with expansion function, and

[0026] - a second valve outlet of the second 3 / 2-way refrigerant valve with expansion function is connected to the ambient heat exchanger and a first valve outlet of the second 3 / 2-way refrigerant valve with expansion function is connected to a receiver and a check valve, and

[0027] - the ambient heat exchanger is connected via the high-pressure side of an internal heat exchanger to the check valve and a refrigerant valve with expansion function, wherein

[0028] - the receiver and the refrigerant valve with expansion function are connected to the refrigerant valve with expansion function and the refrigerant valve with expansion function, wherein

[0029] - the suction side of the compressor is connected to the evaporator via the internal low-pressure heat exchanger side and to the chiller via a refrigerant collector, and the refrigerant collector and the chiller are connected to the second valve outlet of the first 3 / 2-way refrigerant valve with expansion function, or

[0030] - the suction side of the compressor is connected to the evaporator and the chiller via the internal heat exchanger low-pressure side and the second valve outlet of the first 3 / 2-way refrigerant valve with expansion function is connected to the refrigerant collector, or

[0031] - the suction side of the compressor is connected to the evaporator and the chiller via the refrigerant collector and the internal heat exchanger low-pressure side and the second valve outlet of the first 3 / 2-way refrigerant valve with expansion function is connected to the refrigerant collector.

[0032] The refrigeration system and heat pump arrangement is preferably characterised in that an air PTC is provided in an air-conditioning device in addition to the heating condenser or the water-cooled condenser for heating the air for the vehicle cabin.

[0033] Advantageously, the receiver is designed as a refrigerant collector and refrigerant drier at a high-pressure level of the refrigerant.

[0034] The valve in the bypass is preferably designed as a magnet valve, also referred to as a solenoid valve.

[0035] The second 3 / 2-way refrigerant valve with expansion function has a first valve outlet, a second valve outlet and a valve inlet, wherein the valve inlet is connected to the heating condenser or the water-cooled condenser and the first valve outlet is connected to the receiver and the check valve and the second valve outlet is connected to the ambient heat exchanger.

[0036] The first 3 / 2-way refrigerant valve with expansion function downstream of the compressor has a first valve outlet, a second valve outlet and a valve inlet, wherein the valve inlet is connected to the compressor on the high-pressure side and the first valve outlet is connected to the ambient heat exchanger and the second valve outlet is connected to the refrigerant collector.

[0037] The object of the invention is achieved in particular by a method for operating a refrigeration system and heat pump arrangement for actively cooling the vehicle cabin and the battery in refrigeration system operation at ambient temperatures of more than 30°C, in that the refrigerant reaches the ambient heat exchanger downstream of the compressor via the first 3 / 2-way refrigerant valve and condenses, via the internal heat exchanger high-pressure side, the check valve reaches the receiver, after which a first refrigerant mass partial flow flows to the refrigerant valve with expansion function and is relaxed there and evaporates in the evaporator with heat absorption from the air for cooling the vehicle cabin and is conducted via the internal heat exchanger low-pressure side to the compressor and a further refrigerant mass partial flow is conducted to the refrigerant valve with expansion function and relaxed there, after which refrigerant evaporates in the chiller and cools a battery cooling circuit and a second refrigerant partial flow is guided to the suction side of the compressor via the refrigerant collector.

[0038] The object of the invention is achieved in particular by a method for operating a refrigeration system and heat pump arrangement for actively cooling the vehicle cabin in refrigeration system operation at ambient temperatures of more than 30°C, in that the refrigerant reaches the ambient heat exchanger downstream of the compressor via the first 3 / 2-way refrigerant valve and condenses, via the internal heat exchanger high-pressure side, the check valve reaches the receiver, after which the refrigerant flows to the refrigerant valve with expansion function and is relaxed there and evaporates in the evaporator with heat absorption from the air for cooling the vehicle cabin and is conducted to the compressor via the internal heat exchanger low-pressure side.

[0039] The object of the invention is achieved in particular by a method for operating a refrigeration system and heat pump arrangement for actively cooling the battery in refrigeration system operation at ambient temperatures of more than 15°C, in that the refrigerant reaches the ambient heat exchanger downstream of the compressor via the first 3 / 2-way refrigerant valve and condenses, via the internal heat exchanger high-pressure side, the check valve reaches the receiver, after which the refrigerant is conducted to the refrigerant valve with expansion function and is relaxed there and evaporates in the chiller and cools a battery cooling circuit, after which the refrigerant is guided to the suction side of the compressor via the refrigerant collector.

[0040] The object of the invention is achieved in particular by a method for operating a refrigeration system and heat pump arrangement for reheat mode of the vehicle cabin in refrigeration system operation and for actively cooling the battery at ambient temperatures of more than 15°C, in that the refrigerant, downstream of the compressor, emits heat in the heating condenser or in the water-cooled condenser, subsequently is relaxed to a medium pressure level in the second 3 / 2-way refrigerant valve with expansion function and emits heat in the ambient heat exchanger, is conducted to the refrigerant valve with expansion function via the internal heat exchanger high-pressure side, the check valve and the receiver and relaxed to a low-pressure level and in that a refrigerant mass partial flow evaporates in the evaporator with heat absorption from the air and is conducted to the compressor via the internal heat exchanger low-pressure side and a further refrigerant mass partial flow is conducted to the refrigerant valve with expansion function and relaxed there, after which refrigerant evaporates in the chiller and cools a battery cooling circuit and the refrigerant mass partial flow is guided to the suction side of the compressor via the refrigerant collector.

[0041] The object of the invention is achieved in particular by a method for operating a refrigeration system and heat pump arrangement for reheat mode of the vehicle cabin in refrigeration system operation at ambient temperatures of more than 15 °C, in that the refrigerant, downstream of the compressor, emits heat in the heating condenser or in the water-cooled condenser, subsequently is relaxed to a medium pressure level in the second 3 / 2-way refrigerant valve with expansion function and is conducted to the refrigerant valve with expansion function via the ambient heat exchanger, the internal heat exchanger high-pressure side, the check valve and the receiver and relaxed to a low-pressure level and evaporates in the evaporator with heat absorption from the air and is conducted to the compressor via the internal heat exchanger low-pressure side.

[0042] The object of the invention is achieved in particular by a method for operating a refrigeration system and heat pump arrangement for reheat mode of the vehicle cabin in heat pump operation at ambient temperatures of more than 0 °C, in that the refrigerant, downstream of the compressor, emits heat in the heating condenser or in the water-cooled condenser, subsequently is conducted to the refrigerant valve with expansion function via the second 3 / 2-way refrigerant valve and via the receiver and relaxed, subsequently is evaporated in the evaporator with heat absorption from the air and is conducted to the compressor via the internal heat exchanger low-pressure side, wherein the internal heat exchanger high-pressure side is not flowed through by refrigerant.

[0043] The object of the invention is achieved in particular by a method for operating a refrigeration system and heat pump arrangement for reheat mode of the vehicle cabin in heat pump operation and using the ambient hat at ambient temperatures of more than 0°C, in that the refrigerant, downstream of the compressor, emits heat in the heating condenser or in the water-cooled condenser, subsequently is conducted to the receiver via the second 3 / 2-way refrigerant valve and, downstream of the receiver, a first refrigerant mass partial flow is relaxed in the refrigerant valve with expansion function and absorbs heat in the ambient heat exchanger, subsequently is guided to the refrigerant collector via the shut-off valve in bypass to the first 3 / 2-way refrigerant valve and a second refrigerant mass partial flow is relaxed in the refrigerant valve with expansion function and evaporates in the evaporator with heat absorption from the air and is conducted to the compressor.

[0044] The object of the invention is achieved in particular by a method for operating a refrigeration system and heat pump arrangement for reheat mode of the vehicle cabin in heat pump operation and using vehicle waste heat at ambient temperatures of more than 0°C, in that the refrigerant, downstream of the compressor, emits heat in the heating condenser or in the water-cooled condenser, subsequently is conducted via the second 3 / 2-way refrigerant valve and the receiver and, downstream of the receiver, a first refrigerant mass partial flow is conducted to the refrigerant valve with expansion function and relaxed and condenses in the condenser with heat absorption from the air and a second refrigerant mass partial flow, downstream of the receiver, is relaxed in the refrigerant valve with expansion function and absorbs heat in the chiller and subsequently is conducted to the compressor via the refrigerant collector.

[0045] The object of the invention is achieved in particular by a method for operating a refrigeration system and heat pump arrangement for reheat mode of the vehicle cabin in heat pump operation and using ambient heat and vehicle waste heat at ambient temperatures of more than 0°C, characterised in that the refrigerant, downstream of the compressor, emits heat in the heating condenser or in the water-cooled condenser, subsequently is conducted via the second 3 / 2-way refrigerant valve and the receiver and, downstream of the receiver, a first refrigerant mass partial flow is conducted to the refrigerant valve with expansion function and relaxed and in the condenser is condensed with heat absorption from the air and a second refrigerant mass partial flow, downstream of the receiver, is relaxed in the refrigerant valve with expansion function and absorbs heat in the chiller and subsequently is conducted to the compressor via the refrigerant collector and a third refrigerant mass partial flow, downstream of the receiver, is relaxed in the refrigerant valve with expansion function and absorbs heat in the ambient heat exchanger and subsequently is guided to the refrigerant collector via the shut-off valve in bypass to the first 3 / 2-way refrigerant valve and conducted to the compressor via the refrigerant collector.

[0046] The object of the invention is achieved in particular by a method for operating a refrigeration system and heat pump arrangement in heat pump operation and using ambient heat at ambient temperatures higher than -30 °C, in that the refrigerant, downstream of the compressor, emits heat in the heating condenser or in the water-cooled condenser, subsequently is conducted to the receiver via the second 3 / 2-way refrigerant valve and, downstream of the receiver, is relaxed in the refrigerant valve with expansion function and absorbs heat in the ambient heat exchanger and subsequently is guided to the refrigerant collector via the shut-off valve in bypass to the first 3 / 2-way refrigerant valve and conducted to the compressor via the refrigerant collector.

[0047] The object of the invention is achieved in particular by a method for operating a refrigeration system and heat pump arrangement in heat pump operation and using vehicle waste heat at ambient temperatures higher than 30 °C, in that the refrigerant, downstream of the compressor, emits heat in the heating condenser or in the water-cooled condenser, subsequently is conducted to the receiver via the second 3 / 2-way refrigerant valve and, downstream of the receiver, is relaxed in the refrigerant valve with expansion function, evaporated in the chiller and conducted to the compressor via the refrigerant collector.

[0048] The object of the invention is achieved in particular by a method for operating a refrigeration system and heat pump arrangement in heat pump operation and using ambient heat and vehicle waste heat at ambient temperatures higher than -30°C, in that the refrigerant, downstream of the compressor, emits heat in the heating condenser or in the water-cooled condenser, subsequently is conducted to the receiver via the second 3 / 2-way refrigerant valve and, downstream of the receiver, a first refrigerant mass partial flow is relaxed in the refrigerant valve with expansion function and absorbs heat in the ambient heat exchanger and subsequently is conducted to the refrigerant collector via the shut-off valve in the bypass to the first 3 / 2-way refrigerant valve and is conducted to the compressor via the refrigerant collector and a second refrigerant mass partial flow is relaxed in the refrigerant valve with expansion function, evaporated in the chiller and conducted to the compressor via the refrigerant collector.

[0049] The object of the invention is achieved in particular by a method for operating a refrigeration system and heat pump arrangement in heat pump operation and using a hot gas circuit of the refrigerant at ambient temperatures higher than -30°C, in that the refrigerant, downstream of the compressor, emits heat in the heating condenser or in the water-cooled condenser, subsequently is guided to the receiver via the second 3 / 2-way refrigerant valve and, downstream of the receiver, is guided to the refrigerant valve with expansion function and relaxed, evaporates in the chiller and is conducted to the compressor via the refrigerant collector.

[0050] The object of the invention is achieved in particular by a method for operating a refrigeration system and heat pump arrangement in de-icing operation at ambient temperatures higher than -30°C, in that the refrigerant, downstream of the condenser, reaches the ambient heat exchanger via the first 3 / 2-way refrigerant valve and condenses, reaches the receiver via the check valve, after which the refrigerant is conducted to the refrigerant valve with expansion function and relaxed there and evaporates in the chiller and cools a battery cooling circuit, after which the refrigerant is guided to the suction side of the compressor via the refrigerant collector.

[0051] In the sense of the invention, a heating condenser is to be understood as a heat exchanger which, within the air-conditioner of the vehicle, emits heat to the air flow of the air-conditioner for heating the vehicle cabin. As the ambient heat exchanger, a heat exchanger is provided which absorbs heat from the ambient air in the heat pump operation of the arrangement as a radiator or releases heat to the ambient air in refrigeration system operation.

[0052] A chiller is a heat exchanger which is integrated into the refrigerant circuit on one side and into a coolant circuit on the other side, wherein the chiller supplies a battery heat exchanger and a drive train cooler with cooling on the coolant side, for example, and emits heat on the refrigerant side.

[0053] The refrigerant collector is also referred to as an accumulator and can optionally also be embodied and operated as a separator for liquid refrigerant upstream of the compressor.

[0054] A bypass is to be understood as a refrigerant line which bypasses a component or a train of the refrigerant circuit or guides part of the refrigerant mass flow parallel to the relevant component.

[0055] The coolant or heat transfer medium circuits of the vehicle are thermally coupled to the coolant circuit via the chiller or the water-cooled condenser and generally contain a water-glycol mixture which, depending on the operating state of the system, functions as coolant or also as heat transfer medium.

[0056] Direct heating according to layout A is understood to mean heating with the aid of a refrigerant circuit, whereas indirect heating according to layout B is understood to mean heat transfer via a heat transfer medium. Thus, the heating condenser is integrated on one side into the refrigerant circuit of the heat pump and on the other side emits the heat directly to the air to heat the vehicle cabin, whereas the water-cooled condenser absorbs the condensation heat of the refrigerant and transfers it to a heat transfer medium circuit with water as heat transfer medium, in which a heating heat exchanger is integrated, which then emits the heat indirectly to the air to heat the vehicle cabin.

[0057] The concept of the invention is that two groups of system interconnections are proposed. Group Layout A concerns direct heating systems and Group Layout B concerns indirect heating systems.

[0058] The circuits of group A are designed for operation with a direct heat exchanger, referred to as a heating condenser, within the air-conditioning device, in which heat from the refrigerant circuit is transferred directly to the air flowing into the cabin, while the circuits of group B are designed for operation with an indirect heat exchanger, a water-cooled condenser, in which heat from the refrigerant circuit is first transferred to a heat transfer medium circuit, which is not represented in the scheme. The generated heat is transferred by the heat transfer medium, which flows through the heating register, the heating heat exchanger, inside the air-conditioning device. In this way, heat from the refrigerant circuit is transferred indirectly via a heat transfer medium circuit to the air flowing into the cabin. The heat transfer medium circuit is operated, for example, with a coolant based on water as the heat transfer medium fluid, and correspondingly the condenser of the coolant circuit is referred to as a water-cooled condenser.

[0059] System layouts 1, 2, and 3 are distinguished within a group. These differ from one another in the connection of the evaporator and the chiller to the suction side of the compressor.

[0060] In the system layout 1, the partial mass flow of the refrigerant coming from the evaporator is conducted through the low-pressure side of the internal heat exchanger, also referred to as IHX, which is directly connected to the suction line of the compressor. The second partial mass flow of the refrigerant coming from the chiller is guided through the accumulator, also referred to as a refrigerant collector. The mass flow at the outlet of the accumulator is combined with the mass flow at the outlet of the IHX on the low-pressure side of the compressor in the suction line upstream of the compressor inlet.

[0061] In the system layout 2, the partial mass flows coming from the evaporator and the chiller are combined and guided through the low-pressure side of the internal heat exchanger, low-pressure side IHX. The outlet of the internal heat exchanger low-pressure side is connected to the suction line of the compressor. In this case, the accumulator is bypassed.

[0062] In the system layout 3, the partial mass flows coming from the evaporator and the chiller are combined and guided through the low-pressure side of the IHX as a total refrigerant mass flow as with system layout 2. The IHX is then connected to the accumulator inlet line in a manner different from system layout 2. In this case, the entire refrigerant mass flow always flows through the accumulator before reaching the compressor.

[0063] One of the important features of the proposed system circuits is the integration of the collector bottle into the refrigerant circuit, also referred to as the receiver. The receiver is preferably equipped with an additional function of the dryer for the refrigerant. The use of a collector bottle as a refrigerant container at high pressure allows the adjustment of the required refrigerant filling between the refrigeration system AC and the heat pump WP mode. Furthermore, the expansion valve can always be charged with a liquid refrigerant phase upstream of the evaporator, which considerably reduces the risk of chattering noises in the evaporator. Even the smallest amounts of gas bubbles in the flow generate a continuous chattering noise in the evaporator, which can be perceived as disturbing by occupants in the interior.

[0064] Further essential components of the system are the 3 / 2-way refrigerant valves, which possess an expansion function, or are operated therewith, depending on the employment and method variant.

[0065] A first 3 / 2-way refrigerant valve is arranged between the high-pressure outlet of the compressor and the heating condenser in layout A, the direct heater, and the water-cooled condenser in layout B, the indirect heater.

[0066] The 3 / 2-way refrigerant valves possess a valve inlet and a first and a second valve outlet.

[0067] On the one hand, the refrigerant flow can be conducted around the heating condenser or water-cooled condenser via the valve inlet and the first valve outlet of the first 3 / 2-way refrigerant valve. This contributes to reducing the pressure drop on the high pressure side of the refrigerant circuit and the heat losses in the air-conditioning device, resulting in higher efficiency, a higher COP of the system.

[0068] On the other hand, the refrigerant flow can be conducted via the valve inlet and the second valve outlet of the first 3 / 2-way refrigerant valve in order to supply a part of the hot refrigerant gas from the compressor outlet line to the accumulator inlet on the suction side. This hot gas bypass allows the system to be operated at a higher suction pressure, resulting in a higher refrigerant mass flow compared to a system without a hot gas bypass. In this case, the heating performance in heat pump operation can be considerably increased.

[0069] The second 3 / 2-way refrigerant valve possesses two main functions.

[0070] The second 3 / 2-way refrigerant valve can be used to switch between refrigeration system operation A / C and heat pump operation HP.

[0071] On the one hand, the refrigerant flow can reversed through the outer ambient heat exchanger (OHX) via the valve inlet and the first valve outlet of the second 3 / 2-way refrigerant valve.

[0072] On the other hand, the refrigerant flow can emit heat from the refrigerant circuit to the ambient air via the valve inlet and the second valve outlet of the second 3 / 2-way refrigerant valve in refrigeration system operation, whereas, in heat pump, operation, heat is absorbed from the ambient air in order to evaporate the refrigerant in the ambient heat exchanger in the evaporator operation.

[0073] In doing to, the pressure level in the heating condenser is increased in comparison with the pressure level in the ambient heat exchanger in reheating mode (reheat). An increased pressure level leads to higher heating performance and a higher COP of the system.

[0074] The shut-off valve closes the bypass between the high-pressure and low-pressure sides in A / C operation. In heat pump operation, the valve is opened in order to conduct the refrigerant from the ambient heat exchanger outlet to the accumulator inlet on a way as short as possible in heat pump operation, which leads to a significantly lower pressure drop and a higher efficiency of the heat pump system.

[0075] Three refrigerant valves with expansion function are included in the refrigerant circuit in order to be able to carry out all methods. Alternatively to the designs with separate refrigerant valves, as shown in the following figures, the design of the refrigerant circuit is provided by combining the individual refrigerant valves into a four-way valve with expansion function. Again, alternatively, the combination of the refrigerant valves with expansion function upstream of the evaporator and the chiller to form a three-way valve with expansion function as well as a separate refrigerant valve with expansion function downstream of the receiver is provided.

[0076] The indicated system configurations of the refrigeration system and heat pump circuits are capable of meeting the entire requirements for the heat management of a modern electric vehicle with a minimum number of components, as a result of which the overall system costs can be significantly reduced.

[0077] All requirements for the thermal management of an electric vehicle with heating and cooling are covered. In particular, the cabin cooling, the dehumidification and heating as well as the active HV battery cooling are realised.

[0078] Furthermore, a hot gas cycle for a higher heating performance and dynamics is employed.

[0079] The direct and indirect heating of the cabin makes the refrigeration system and heat pump arrangements compatible with all types of air-conditioners, which are also referred to as HVAC types.

[0080] A unique mode for defrosting / de-icing the ambient heat exchanger in heat pump mode complements the overall concept.

[0081] The advantages are, in summary, a high performance and efficiency of the system, a high degree of waste heat recovery, an optimisation for the pressure drop in the air-conditioner and heat pump mode and a very efficient reheating function by dividing the mass flow into three parallel refrigerant mass flows in selected modes.

[0082] The system is also optimised for NVH problems of sound and noise exposure, because there is only a small risk of hissing noise by ensuring the liquid phase of the refrigerant in the receiver, for example on the high-pressure side. Furthermore, there is a low risk of oil and refrigerant deposits in the circuit.

[0083] A robust control strategy is also advantageous. Despite slight differences in layout, the same control strategy can be applied to all systems, which leads to a low complexity of the system control in all modes.

[0084] Further details, features and advantages of designs of the invention will become apparent from the following description of exemplary embodiments with reference to the accompanying drawings. Figures 1 to 34 show flow diagrams of refrigeration system and heat pump arrangements in different modes:

[0085] Fig. 1: arrangement for direct heating group A with layout 1,

[0086] Fig. 2: arrangement for direct heating group A with layout 2,

[0087] Fig. 3: arrangement for direct heating group A with layout 3,

[0088] Fig. 4: arrangement for indirect heating group B with layout 1,

[0089] Fig. 5: arrangement for indirect heating group B with layout 2, and

[0090] Fig. 6: arrangement for indirect heating group B with layout 3.

[0091] In Figures 7 to 20, the flow diagrams for different methods are respectively shown for direct heating in group A with layout 1, and in Figures 21 to 34, the flow diagrams for different methods are shown for indirect heating in group B with layout 1, wherein under cabin cooling means the cooling and under cabin heating means the heating of the vehicle cabin by means of the air-conditioning device of the vehicle:

[0092] Figs. 7, 21: #1 flow diagram for refrigeration system operation, cabin cooling and active battery cooling at high ambient temperatures of over 30°C,

[0093] Figs. 8, 22: #2 flow diagram for refrigeration system operation, cabin cooling at high ambient temperatures of over 30°C,

[0094] Figs. 9, 23: #3 flow diagram for refrigeration system operation, active battery cooling at high ambient temperatures of over 30°C and mild ambient temperatures of over 15°C,

[0095] Figs. 10, 24: #4 flow diagram for refrigeration system operation, cabin cooling and reheat and active battery cooling at mild ambient temperatures of over 15°C,

[0096] Figs. 11, 25: #5 flow diagram for refrigeration system operation, cabin cooling and reheat at mild ambient temperatures of over 15°C,

[0097] Figs. 12, 26: #6 flow diagram for heat pump operation, cabin heating and reheat at low ambient temperatures of over 0°C,

[0098] Figs. 13, 27: #7 flow diagram for heat pump operation, reheat, heat source, ambient air at low ambient temperatures of over 0°C,

[0099] Figs. 14, 28: #8 flow diagram for heat pump operation, reheat, heat source, waste heat at low ambient temperatures of over 0°C,

[0100] Figs. 15, 29: #9 flow diagram for heat pump operation, reheat, heat source, ambient air and waste heat at low ambient temperatures of over 0°C,

[0101] Figs. 16, 30: #10 flow diagram for heat pump operation, heat source, ambient air at very low ambient temperatures of -30°C to 0°C,

[0102] Figs. 17, 31: #11 flow diagram for heat pump operation, heat source, waste heat at very low ambient temperatures of -30°C to 0°C,

[0103] Figs. 18, 32: #12 flow diagram for heat pump operation, heat source, ambient air and waste heat at very low ambient temperatures of -30°C to 0°C,

[0104] Figs. 19, 33: #13 flow diagram for heat pump operation, hot gas circuit at very low ambient temperatures of -30°C to 0°C,

[0105] Figs. 20, 34: #14 flow diagram for de-icing at very low ambient temperatures of -30°C to 0°C,

[0106] Fig. 35: diagram of flow curve of 3 / 2-way refrigerant valve with expansion function,

[0107] Fig. 36a: schematic representation of the 3 / 2-way refrigerant valve with expansion function, and

[0108] Fig. 36b: switching characteristics of the 3 / 2-way refrigerant valve with expansion function.

[0109] The fluid connections, the pipelines between the components of the refrigerant circuit of the thermal management system, are represented with a double line in Figures 1 to 6.

[0110] In Figure 1 to Figure 3, circuits for the direct heating of the vehicle cabin via the heating condenser 2 within an air-conditioning device 20 are shown.

[0111] The compressor 1 is connected on the high-pressure side to the first 3 / 2-way refrigerant valve with expansion function 8 at the valve inlet 23. Furthermore, the high-pressure side of the compressor 1 is interconnected with the heating condenser 2 in the air-conditioning device 20. From there, the refrigerant reaches the valve inlet 23 of the second 3 / 2-way refrigerant valve with expansion function 3 (EXV). There is a connection to the receiver 15 as well as to a check valve 16 via the first valve outlet 21 of the second 3 / 2-way refrigerant valve 3. The outlet side of the receiver 15 is connected to the refrigerant valve with expansion function 5 and the refrigerant valve with expansion function 14. The refrigerant valve 14 is also connected to the internal heat exchanger high-pressure side 12 and the check valve 16. The second 3 / 2-way refrigerant valve 3 is connected to the ambient heat exchanger 4, the first valve outlet 21 of the first 3 / 2-way refrigerant valve 8 and to the shut-off valve 17 via its second valve outlet 22. The ambient heat exchanger 4 is joined with the internal heat exchanger high-pressure side 12 on the other side. The shut-off valve 17 has a connection to the second valve outlet 22 of the first 3 / 2-way refrigerant valve 8 and to the refrigerant collector 11.

[0112] The internal heat exchanger of the refrigeration system and heat pump functionally transmits heat of the refrigerant of higher temperature from a high-pressure side to refrigerant of lower temperature on a low-pressure side. Consequently, the high-pressure side and the low-pressure side of the internal heat exchanger of the circuit are thermally connected and are generally embodied in one structural unit. For reasons of clarity of the line guiding only, the internal heat exchanger high-pressure side 12 and the internal heat exchanger low-pressure side 13 are represented in the circuits in detachment from one another, even though the internal heat exchanger is functionally a component of the refrigerant circuit and is embodied in a structural unit.

[0113] The vehicle cabin air is conditioned in the air-conditioning device 20 of the vehicle. In the broader sense, this is understood to mean, depending on the requirement, the cooling, heating and dehumidification of the air introduced into the vehicle cabin from the air-conditioning device 20. Additional cabin heating performance can be achieved by employing an air PTC 7, an air-side heating element, in the air-conditioning device 20.

[0114] Three refrigerant valves with expansion function with reference numerals 5, 10 and 14 are included in the refrigerant circuits of Figures 1 to 6 in order to be able to carry out all methods. Alternatively to the designs with separate refrigerant valves, as represented as drawings in the figures, the design of the refrigerant circuit is provided by combining the individual refrigerant valves into a four-way valve with expansion function, not represented.

[0115] Again, alternatively, the combination of the refrigerant valves with expansion function 5 and 10 upstream of the evaporator 6 and the chiller 9 to form a three-way valve with expansion function as well as a separate refrigerant valve with expansion function 14 downstream of the receiver 15 is provided.

[0116] The system architecture enables flexible operation of the refrigeration system and the heat pump system in various operating modes, such as cooling, heating and dehumidification, with minimal employment of expansion and directional valves.

[0117] In Figures 4 to 6, circuits for indirect heating of the vehicle cabin via the water-cooled condenser 18 are shown, which is connected to the heating heat exchanger 19 within an air-conditioning device 20 by means of a coolant or heat transfer medium circuit, not represented. The heat absorbed by the heat transfer medium circuit in the water-cooled condenser 18 is transferred to the vehicle cabin air via the heating heat exchanger 19 in the air-conditioning device 20.

[0118] In contrast to Figures 1 to 3, in Figures 4 to 6, the compressor 1 is connected on the high-pressure side, next to the valve inlet 23 of the first 3 / 2-way refrigerant valve 8, to the water-cooled condenser 18, and the latter is connected to the valve inlet 23 of the second 3 / 2-way refrigerant valve 3. The further high-pressure side components are arranged and linked analogously to Figures 1 to 3.

[0119] The refrigerant circuits of Figures 1 to 3 and 4 to 6 differ in the configuration on the suction side of the compressor 1; these variants are referred to as layout 1 to 3.

[0120] The layout 1 is shown in Figure 1 and Figure 4, wherein the receiver 15 is connected to the refrigerant valve with expansion function 5 and to the refrigerant valve with expansion function 10. The refrigerant valve with expansion function 5 is functionally followed in the flow direction of the refrigerant by the evaporator 6 within the air-conditioning device 20 and the refrigerant valve with expansion function 10 is functionally followed by the chiller 9. The evaporator 6 is connected on the outlet side to the internal heat exchanger low-pressure side 13, which is connected on the outlet side to the suction side of the compressor 1 and to the refrigerant collector 11. The refrigerant collector 11 is also connected to the outlet of the chiller 9, as a result of which the circuit is closed.

[0121] The layout 2 according to Figures 3 and 5 is characterised in that the receiver 15 is also connected to the refrigerant valve with expansion function 5 and parallel to the refrigerant valve with expansion function 10, wherein the evaporator 6 is downstream of the refrigerant valve 5 and the chiller 9 parallel to the evaporator 6 is downstream of the refrigerant valve 10. The outlets of the evaporator 6 and chiller 9 are combined in the inlet of the internal heat exchanger low-pressure side 13. The outlet of the internal heat exchanger low-pressure side 13 is connected to the suction side of the compressor 1 and the refrigerant collector 11.

[0122] Finally, the core of the layout 3 according to Figure 3 and Figure 6 is, that, as compared to layout 2, the internal heat exchanger low-pressure side 13 is connected to the suction side of the compressor 1 on the outlet side via the refrigerant collector 11 and the total refrigerant mass flow is guided to the compressor 1 via the refrigerant collector 11.

[0123] The system is preferably designed for operation with the refrigerants R1234yf and R134a.

[0124] For Figures 7 to 34, it applies that in the corresponding method mode non-flown refrigerant lines to non-active components are represented in thin dashed lines and active, flowed refrigerant lines are represented in active components in double lines thicker relative thereto.

[0125] The flow direction of the refrigerant in the method mode of the respective flow diagram is indicated by triangles in the figures, wherein black-filled triangles symbolise refrigerants at higher temperature and pressure levels and white-filled triangles symbolise refrigerants at lower temperature and pressure levels.

[0126] The circuit state and function of the valves are indicated by the representation of the symbols. The valves are represented as two triangles touching one another with a tip over a small circle and, projecting laterally, a larger circle with a cross is arranged as an adjusting element. If the triangle symbols are represented only as an outline and empty or white, the valve is opened. If the triangle symbols are completely filled in black, the valves are closed. If the valves, as far as is provided, are operated with the expansion function, the larger circles, which symbolise the adjusting elements, are filled in black and represented with a white cross. Without expansion function, the larger circles for the adjusting elements are shown in white with a black cross. Consequently, a valve in expansion function possesses two white triangles and a black circle of the adjusting element with a white cross.

[0127] In Fig. 7 and Fig. 21, the flow diagram for refrigeration system operation, cabin cooling and active battery cooling at high ambient temperatures of over 30°C is shown.

[0128] Fig. 7 represents the configuration for the direct heating of the vehicle cabin via the heating condenser 2 and Fig. 21 represents the configuration for the indirect heating via the water-cooled condenser 18 and the heating heat exchanger 19.

[0129] In this mode, the refrigerant flows downstream of the compressor 1 via the first 3 / 2-way refrigerant valve with expansion function 8 through the air-cooled ambient heat exchanger (OHX) 4, wherein condensation heat is emitted to the environment. The refrigerant mass flow passes the internal heat exchanger high-pressure side 12 and reaches the receiver 15 via the check valve 16. Subsequently, a first refrigerant mass partial flow is expanded into the evaporator 6 with the refrigerant valve with expansion function 5 arranged upstream of the evaporator 6 in order to cool the air flowing through the air-conditioning device 20 and the evaporator 6 into the cabin.

[0130] The first refrigerant mass partial flow is guided from the evaporator 6 via the internal heat exchanger low-pressure side 13 to the suction side of the compressor 1. In parallel, a second refrigerant mass partial flow in the refrigerant valve with expansion function 10 is expanded into the chiller 9, via which, as indicated in the figure, the battery is cooled by means of a coolant circuit. The second refrigerant mass partial flow is supplied to the suction side of the compressor 1 downstream of the chiller 9 via the refrigerant collector 11 and combined with the first refrigerant mass partial flow.

[0131] In Fig. 8 and Fig. 22, the flow diagram for refrigeration system operation, cabin cooling at high ambient temperatures of over 30°C is shown.

[0132] In this mode, in contrast to the mode described above, the refrigerant mass flow downstream of the receiver 15 is not divided, but the entire refrigerant mass flow is guided via the evaporator 6 of the air-conditioning device 20. This makes available the entire cooling performance for cabin cooling.

[0133] In Fig. 9 and Fig. 23, the flow diagram for refrigeration system operation, active battery cooling at high ambient temperatures of over 30°C and mild ambient temperatures of over 15°C is represented. In this mode, the refrigerant mass flow downstream of the receiver 15 is not divided either, but the entire refrigerant mass flow is guided via the chiller 9. This makes available the entire cooling performance for battery cooling.

[0134] In Fig. 10 and Fig. 24, the flow diagram for refrigeration system operation, cabin cooling and reheat and active battery cooling at mild ambient temperatures of over 15°C is shown.

[0135] In the case of vehicle air-conditioning, a reheating mode is understood to mean that the air to be supplied to the vehicle cabin is first cooled and dehumidified in the air-conditioning device 20 and subsequently is heated to a desired temperature. By reducing the humidity of the vehicle cabin air, misting of the vehicle windows is decreased or prevented.

[0136] In this mode, the refrigerant flows through the heating condenser 2 according to Fig. 10 and the water-cooled condenser 18 according to Fig. 24 to the air-cooled ambient heat exchanger 4, wherein condensation heat is emitted to the ambient air. Regulation of the heat emission to the ambient air is via the second 3 / 2-way refrigerant valve with expansion function 3 which is arranged between the heating condenser 2 or the water-cooled condenser 18 and the ambient heat exchanger 4. The refrigerant is thus expanded to a medium pressure level into the ambient heat exchanger 4.

[0137] Downstream of the ambient heat exchanger 4, the refrigerant reaches the receiver 15 via the internal heat exchanger high-pressure side 12 and the check valve 16.

[0138] Subsequently, a first refrigerant mass partial flow is expanded into the evaporator 6 with the refrigerant valve with expansion function 5 arranged upstream of the evaporator 6 in order to cool the air flowing through the air-conditioning device 20 and the evaporator 6 into the cabin and thus to dehumidify it.

[0139] Subsequently, the vehicle cabin air is reheated through the heating condenser 2 or the heating heat exchanger 19 of the air-conditioning device 20 and brought to the desired vehicle cabin temperature. The heat flow, which is required for reheating the air flow to the cabin, is lower than the heat flow extracted from the air flow in the evaporator 6. The heat extraction of the vehicle cabin air described above and the optionally associated humidity extraction and the subsequent heating to the desired temperature of the air for the vehicle cabin is referred to as reheating.

[0140] The first refrigerant mass partial flow is guided from the evaporator 6 via the internal heat exchanger low-pressure side 13 to the suction side of the compressor 1. In parallel, a second refrigerant mass partial flow in the refrigerant valve with expansion function 10 is expanded into the chiller 9, via which, as indicated in the figure, the battery is cooled by means of a coolant circuit. The second refrigerant mass partial flow is supplied to the suction side of the compressor 1 downstream of the chiller 9 via the refrigerant collector 11 and combined with the first refrigerant mass partial flow.

[0141] In Fig. 11 and Fig. 25, the flow diagram for refrigeration system operation, cabin cooling and reheat at mild ambient temperatures of over 15°C is shown. In contrast to the above-described Figures 10 and 24, no active battery cooling is operated in this mode, so that the entire refrigerant mass flow is available for the reheat function of the air-conditioning device 20.

[0142] In Fig. 12 and Fig. 26, the flow diagram for heat pump operation, cabin heating and reheat at low ambient temperatures of over 0°C is represented.

[0143] In this mode, the refrigerant flows through the heating condenser 2 according to Fig. 12 or the water-cooled condenser 18 according to Fig. 26 via the second 3 / 2-way refrigerant valve 3 to the receiver 15. The second 3 / 2-way refrigerant valve 3 does not have any expansion function.

[0144] In this mode, the refrigerant mass flow is guided via the evaporator 6 of the air-conditioning device 20 after expansion in the refrigerant valve with expansion function 5. Subsequently, the refrigerant flows to the suction side of the compressor 1 via the non-functional internal heat exchanger low-pressure side 13.

[0145] In Fig. 13 and Fig. 27, the flow diagram for heat pump operation, reheat, heat source, ambient air at low ambient temperatures of over 0°C is shown.

[0146] In this mode, the refrigerant flows through the heating condenser 2 according to Fig. 13 or the water-cooled condenser 18 according to Fig. 27 via the second 3 / 2-way refrigerant valve 3 to the receiver 15. The second 3 / 2-way refrigerant valve 3 does not have any expansion function.

[0147] Downstream of the receiver 15, a first refrigerant mass partial flow is relaxed in the refrigerant valve with expansion function 14 and absorbs ambient heat in the ambient heat exchanger 4, reaches the suction side of the compressor 1 via the opened shut-off valve 17 to the refrigerant collector 11.

[0148] In parallel, a second refrigerant mass partial flow is expanded in the refrigerant valve with expansion function 5 and guided to the suction side of the compressor 1 via the evaporator 6 and the internal heat exchanger low-pressure side 13, where the two refrigerant mass partial flows are combined.

[0149] In Fig. 14 and Fig. 28, the flow diagram for heat pump operation, reheat, heat source, waste heat at low ambient temperatures of over 0°C is represented.

[0150] In this mode, the refrigerant flows through the heating condenser 2 according to Fig. 14 or the water-cooled condenser 18 according to Fig. 28 via the second 3 / 2-way refrigerant valve 3 to the receiver 15. The second 3 / 2-way refrigerant valve 3 does not have any expansion function.

[0151] Subsequently, a first refrigerant mass partial flow is expanded into the evaporator 6 with the refrigerant valve with expansion function 5 arranged upstream of the evaporator 6 in order to cool the air flowing through the air-conditioning device 20 and the evaporator 6 into the cabin and thus to dehumidify it.

[0152] Subsequently, the vehicle cabin air is reheated through the heating condenser 2 or the heating heat exchanger 19 of the air-conditioning device 20 and brought to the desired vehicle cabin temperature.

[0153] The first refrigerant mass partial flow is guided from the evaporator 6 via the internal heat exchanger low-pressure side 13 to the suction side of the compressor 1.

[0154] In parallel, a second refrigerant mass partial flow downstream of the receiver 15 is expanded into the chiller 9 in the refrigerant valve with expansion function 10, via which, as indicated in the figures, the battery is cooled by means of a coolant circuit. The second refrigerant mass partial flow is supplied to the suction side of the compressor 1 downstream of the chiller 9 via the refrigerant collector 11 and combined with the first refrigerant mass partial flow.

[0155] In Fig. 15 and Fig. 29, the flow diagram for heat pump operation, reheat, heat source, ambient air and waste heat at low ambient temperatures of over 0°C is shown.

[0156] In this mode, the refrigerant flows through the heating condenser 2 according to Fig. 15 or the water-cooled condenser 18 according to Fig. 29 via the second 3 / 2-way refrigerant valve 3 to the receiver 15. The second 3 / 2-way refrigerant valve 3 does not have any expansion function.

[0157] Downstream of the receiver 15, a first refrigerant mass partial flow is relaxed in the refrigerant valve with expansion function 14 and absorbs ambient heat in the ambient heat exchanger 4, reaches the refrigerant collector 11 via the opened shut-off valve 17 and finally the suction side of the compressor 1.

[0158] In parallel, a second refrigerant mass partial flow downstream of the receiver 15 is expanded in the refrigerant valve with expansion function 5 and guided to the suction side of the compressor 1 via the evaporator 6 and the internal heat exchanger low-pressure side 13, where the two refrigerant mass partial flows are combined.

[0159] A third refrigerant mass partial flow is expanded downstream of the receiver 15 into the chiller 9 in the refrigerant valve with expansion function 10, via which, as indicated in the figures, the battery is cooled by means of a coolant circuit. The third refrigerant mass partial flow is combined with the first refrigerant mass partial flow downstream of the chiller 9 in the refrigerant collector 11 and finally supplied to the suction side of the compressor 1 and combined with the second refrigerant mass partial flow.

[0160] In Fig. 16 and Fig. 30, the flow diagram for heat pump operation, heat source, ambient air at very low ambient temperatures of -30°C to 0°C is represented.

[0161] In this mode, the refrigerant flows through the heating condenser 2 according to Fig. 16 or the water-cooled condenser 18 according to Fig. 30 via the second 3 / 2-way refrigerant valve 3 to the receiver 15. The second 3 / 2-way refrigerant valve 3 does not have any expansion function.

[0162] Downstream of the receiver 15, the entire refrigerant mass flow in the refrigerant valve with expansion function 14 is relaxed, flows through the non-functional internal heat exchanger 12 and absorbs ambient heat in the ambient heat exchanger 4, passes via the opened shut-off valve 17 to the refrigerant collector 11 and finally to the suction side of the compressor 1.

[0163] In Fig. 17 and Fig. 31, the flow diagram for heat pump operation, heat source, waste heat at very low ambient temperatures of -30°C to 0°C is shown.

[0164] In this mode, the refrigerant flows through the heating condenser 2 according to Fig. 17 or the water-cooled condenser 18 according to Fig. 31 via the second 3 / 2-way refrigerant valve 3 to the receiver 15. The second 3 / 2-way refrigerant valve 3 does not have any expansion function.

[0165] In this mode, the refrigerant mass flow downstream of the receiver 15 is relaxed in the refrigerant valve with expansion function 10 and guided via the chiller 9, wherein waste heat and in particular battery waste heat are absorbed by the refrigerant circuit. The refrigerant passes via the refrigerant collector 11 to the suction side of the compressor 1.

[0166] In Fig. 18 and Fig. 32, the flow diagram for heat pump operation, heat source, ambient air and waste heat at very low ambient temperatures of -30°C to 0°C is shown.

[0167] In this mode, the refrigerant flows through the heating condenser 2 according to Fig. 18 or the water-cooled condenser 18 according to Fig. 32 via the second 3 / 2-way refrigerant valve 3 to the receiver 15. The second 3 / 2-way refrigerant valve 3 does not have any expansion function.

[0168] Downstream of the receiver 15, a first refrigerant mass partial flow is relaxed in the refrigerant valve with expansion function 14 and absorbs ambient heat in the ambient heat exchanger 4, reaches the refrigerant collector 11 via the opened shut-off valve 17 and the suction side of the compressor 1.

[0169] In parallel, a second refrigerant mass partial flow is expanded in the refrigerant valve with expansion function 10 and guided via the chiller 9 and the refrigerant collector 11, where the two refrigerant mass partial flows are combined and guided to the suction side of the compressor 1.

[0170] In Fig. 19 and Fig. 33, the flow diagram for heat pump operation, hot gas circuit at very low ambient temperatures of -30°C to 0°C is shown.

[0171] In this mode, a first refrigerant mass partial flow flows via the first 3 / 2-way refrigerant valve with expansion function 8 to the refrigerant collector 11. The second 3 / 2-way refrigerant valve 3 relaxes the first refrigerant mass partial flow.

[0172] The second refrigerant mass partial flow flows through the heating condenser 2 according to Fig. 19 or the water-cooled condenser 18 according to Fig. 33 and reaches the receiver 15. Afterwards, the second refrigerant mass partial flow is relaxed in the refrigerant valve with expansion function 10 and absorbs waste heat in the chiller 9, after which the second refrigerant mass partial flow combines with the first refrigerant mass partial flow in the refrigerant collector 11 and is supplied to the suction side of the compressor 1.

[0173] In Fig. 20 and Fig. 34, the flow diagram for de-icing at very low ambient temperatures of -30°C to 0°C is represented.

[0174] In this mode, the hot refrigerant mass flow flows downstream of the compressor 1 via the first 3 / 2-way refrigerant valve 8 to the ambient heat exchanger 4. The first 3 / 2-way refrigerant valve 8 does not have any expansion function.

[0175] The hot refrigerant gas condenses in the ambient heat exchanger 4 and heats it such that ice possibly formed on the ambient heat exchanger 4 during heat pump operation melts off.

[0176] Downstream of the ambient heat exchanger 4, the refrigerant reaches the receiver 15 and subsequently the refrigerant valve with expansion function 10 via the non-functional internal heat exchanger high-pressure side 12 and the check valve 16, is relaxed there and absorbs waste heat from the battery cooling circuit in the chiller 9 before the refrigerant reaches the suction side of the compressor 1 via the refrigerant collector 11.

[0177] In Fig. 35, a diagram of the flow curve of the 3 / 2-way refrigerant valve with expansion function is represented.

[0178] The abscissa represents the opening of the valve position from 0 to 100%. The ordinate depicts the flow rate between 0 and 100%. Areas A, B, C and D are distinguished.

[0179] In area A, the passage of the valve from the valve inlet 23 to the first valve outlet 21 is represented, wherein the valve is fully opened, the flow rate is 100%.

[0180] In area B, all connections are closed, the flow rate is 0%.

[0181] The area C shows the expansion region, wherein the refrigerant passage is switched from the valve inlet 32 to the second valve outlet 22 through the valve. The first valve outlet 21 is closed. In accordance with the opening characteristic, the flow rate increases moderately.

[0182] Area D shows the fully opened passage from the valve inlet 23 to the second valve outlet 22, wherein the first valve outlet 21 is closed, the flow rate is 100%.

[0183] In Fig. 36a, the 3 / 2-way refrigerant valves with expansion function 3 and 8 are represented schematically.

[0184] The 3 / 2-way refrigerant valve with expansion function 8 and 3 has three connections, which are designated by valve inlet 23, first valve outlet 21 and second valve outlet 22.

[0185] Instead of the 3 / 2-way refrigerant valve with expansion function 8 or 3, individual valves with the corresponding functionalities can alternatively also be employed.

[0186] In Fig. 36b, the switching characteristics of the 3 / 2-way refrigerant valves with expansion function 3 and 8 is represented.

[0187] In area I, the passage from the valve inlet 23 downstream of the first valve outlet 21 is switched, the second valve outlet 22 is closed.

[0188] In area II, all ports are closed, there is no passage for fluid through the valve.

[0189] In area III, the passage from the valve inlet 23 downstream of the second valve outlet 22 is switched, the first valve outlet 21 is closed.

Claims

1.A refrigeration system and heat pump arrangement for heating and cooling battery-operated vehicles, having a refrigerant circuit- with a compressor (1), a heating condenser (2) for direct heat transfer or a water-cooled condenser (18) for indirect heat transfer, a second 3 / 2-way refrigerant valve with expansion function (3), an ambient heat exchanger (4), at least one evaporator (6) with an associated refrigerant valve with expansion function (5) as well as a refrigerant path arranged parallel to the evaporator (6) via a chiller (9) with an upstream refrigerant valve with expansion function (10), wherein- the high-pressure side of the compressor (1) is connected to the heating condenser (2) or the water-cooled condenser (18) and to a valve inlet (23) of a first 3 / 2-way refrigerant valve with expansion function (8) and a second valve outlet (22) of the first 3 / 2-way refrigerant valve with expansion function (8) is connected to a refrigerant collector (11) as well as a first valve outlet (21) of the first 3 / 2-way refrigerant valve with expansion function (8) is connected to the ambient heat exchanger (4), and- a bypass line which can be shut with a shut-off valve (17) is arranged to the first 3 / 2-way refrigerant valve with expansion function (8), and- a second valve outlet (22) of the second 3 / 2-way refrigerant valve with expansion function (3) is connected to the ambient heat exchanger (4) and a first valve outlet (21) of the second 3 / 2-way refrigerant valve with expansion function (3) is connected to a receiver (15) and a check valve (16), and- the ambient heat exchanger (4) is connected via the high-pressure side of an internal heat exchanger (12) to the check valve (16) and a refrigerant valve with expansion function (14), wherein- the receiver (15) and the refrigerant valve with expansion function (14) are connected to the refrigerant valve with expansion function (5) and the refrigerant valve with expansion function (10), wherein- the suction side of the compressor (1) is connected to the evaporator (6) via the internal heat exchanger low-pressure side (13) and to the chiller (9) via a refrigerant collector (11), and the refrigerant collector (11) and the chiller (9) are connected to the second valve outlet (22) of the first 3 / 2-way refrigerant valve with expansion function (8), orthe suction side of the compressor (1) is connected to the evaporator (6) and the chiller (9) via the internal heat exchanger low-pressure side (13) and the second valve outlet (22) of the first 3 / 2-way refrigerant valve with expansion function (8) is connected to the refrigerant collector (11), orthe suction side of the compressor (1) is connected to the evaporator (6) and the chiller (9) via the refrigerant collector (11) and the internal heat exchanger low-pressure side (13) and the second valve outlet (22) of the first 3 / 2-way refrigerant valve with expansion function (8) is connected to the refrigerant collector (11).2.The refrigeration system and heat pump arrangement according to claim 1, characterised in that an air PTC (7) is arranged in an air-conditioning device (20) in addition to the heating condenser (2) or the water-cooled condenser (18) for heating the air for the vehicle cabin.3.The refrigeration system and heat pump arrangement according to claim 1 or 2, characterised in that the receiver (15) is designed as a refrigerant collector and refrigerant drier at a high-pressure level of the refrigerant.4.The refrigeration system and heat pump arrangement according to any one of claims 1 to 3, characterised in that the shut-off valve (17) is formed as a magnet valve.5.The refrigeration system and heat pump arrangement according to any one of claims 1 to 4, characterised in that the second 3 / 2-way refrigerant valve with expansion function (3) has a first valve outlet (21), a second valve outlet (22) and a valve inlet (23), wherein the valve inlet (23) is connected to the heating condenser (2) or the water-cooled condenser (18) and the first valve outlet (21) is connected to the receiver (15) and the check valve (16) and the second valve outlet (22) is connected to the ambient heat exchanger (4).6.The refrigeration system and heat pump arrangement according to any one of claims 1 to 5, characterised in that the first 3 / 2-way refrigerant valve with expansion function (8) has a first valve outlet (21), a second valve outlet (22) and a valve inlet (23), wherein the valve inlet (23) is connected to the compressor (1) on the high-pressure side and the first valve outlet (21) is connected to the ambient heat exchanger (4) and the second valve outlet (22) is connected to the refrigerant collector (11).7.A method for operating a refrigeration system and heat pump arrangement according to any one of claims 1 to 6 for actively cooling the vehicle cabin and the battery in refrigeration system operation at ambient temperatures of more than 30°C, characterised in that the refrigerant, downstream of the compressor (1), reaches the ambient heat exchanger (4) via the first 3 / 2-way refrigerant valve (8) and condenses, reaches the receiver (15) via the internal heat exchanger high-pressure side (12), the check valve (16), after which a first refrigerant mass partial flow flows to the refrigerant valve with expansion function (5) and is relaxed there and evaporates in the evaporator (6) with heat absorption from the air for cooling the vehicle cabin and is conducted to the compressor (1) via the internal heat exchanger low-pressure side (13) and a further refrigerant mass partial flow is conducted to the refrigerant valve with expansion function (10) and relaxed there, after which refrigerant evaporates in the chiller (9) and cools a battery cooling circuit and a second refrigerant partial flow is guided to the suction side of the compressor (1) via the refrigerant collector (11).8.The method for operating a refrigeration system and heat pump arrangement according to any one of claims 1 to 6 for actively cooling the vehicle cabin in refrigeration system operation at ambient temperatures of more than 30°C, characterised in that the refrigerant, downstream of the compressor (1), reaches the ambient heat exchanger (4) via the first 3 / 2-way refrigerant valve (8) and condenses, reaches the receiver (15) via the internal heat exchanger high-pressure side (12), the check valve (16), after which the refrigerant flows to the refrigerant valve with expansion function (5) and is relaxed there and evaporates in the evaporator (6) with heat absorption from the air for cooling the vehicle cabin and is conducted to the compressor (1) via the internal heat exchanger low-pressure side (13).9.The method for operating a refrigeration system and heat pump arrangement according to any one of claims 1 to 6 for actively cooling the battery in refrigeration system operation at ambient temperatures of more than 15°C, characterised in that the refrigerant, downstream of the compressor (1), reaches the ambient heat exchanger (4) via the first 3 / 2-way refrigerant valve (8) and condenses, reaches the receiver (15) via the internal heat exchanger high-pressure side (12), the check valve (16), after which the refrigerant is conducted to the refrigerant valve with expansion function (10) and relaxed there and evaporates in the chiller (9) and cools a battery cooling circuit, after which the refrigerant is guided to the suction side of the compressor (1) via the refrigerant collector (11).10.The method for operating a refrigeration system and heat pump arrangement according to any one of claims 1 to 6 for reheat mode of the vehicle cabin in refrigeration system operation and for actively cooling the battery at ambient temperatures of more than 15°C, characterised in that the refrigerant, downstream of the compressor (1), emits heat in the heating condenser (2) or in the water-cooled condenser (18), subsequently is relaxed to a medium pressure level in the second 3 / 2-way refrigerant valve with expansion function (3) and emits heat in the ambient heat exchanger (4), is conducted to the refrigerant valve with expansion function (5) via the internal heat exchanger high-pressure side (12), the check valve (16) and the receiver (15) and relaxed to a low-pressure level and in that a refrigerant mass partial flow evaporates in the evaporator (6) with heat absorption from the air and is conducted to the compressor (1) via the internal heat exchanger low-pressure side (13) and a further refrigerant mass partial flow is conducted to the refrigerant valve with expansion function (10) and relaxed there, after which refrigerant evaporates in the chiller (9) and cools a battery cooling circuit and the refrigerant mass partial flow is guided to the suction side of the compressor (1) via the refrigerant collector (11).11.The method for operating a refrigeration system and heat pump arrangement according to any one of claims 1 to 6 for reheat mode of the vehicle cabin in refrigeration system operation at ambient temperatures of more than 15°C, characterised in that the refrigerant, downstream of the compressor (1), emits heat in the heating condenser (2) or in the water-cooled condenser (18), subsequently is relaxed to a medium pressure level in the second 3 / 2-way refrigerant valve with expansion function (3) and is conducted to the refrigerant valve with expansion function (5) via the ambient heat exchanger (4), the internal heat exchanger high-pressure side (12), the check valve (16) and the receiver (15) and relaxed to a low-pressure level and evaporates in the evaporator (6) with heat absorption from the air and is conducted to the compressor (1) via the internal heat exchanger low-pressure side (13).12.The method for operating a refrigeration system and heat pump arrangement according to any one of claims 1 to 6 for reheat mode of the vehicle cabin in heat pump operation at ambient temperatures of more than 0°C, characterised in that the refrigerant, downstream of the compressor (1), emits heat in the heating condenser (2) or in the water-cooled condenser (18), subsequently is conducted to the refrigerant valve with expansion function (5) via the second 3 / 2-way refrigerant valve (3) and via the receiver (15) and relaxed, subsequently evaporates in the evaporator (6) with heat absorption from the air and is conducted to the compressor (1) via the internal heat exchanger low-pressure side (13), wherein the internal heat exchanger high-pressure side (12) is not flowed through by refrigerant.13.The method for operating a refrigeration system and heat pump arrangement according to any one of claims 1 to 6 for reheat mode of the vehicle cabin in heat pump operation and using the ambient heat at ambient temperatures of more than 0°C, characterised in that the refrigerant, downstream of the compressor (1), emits heat in the heating condenser (2) or in the water-cooled condenser (18), subsequently is conducted to the receiver (15) via the second 3 / 2-way refrigerant valve (3) and, downstream of the receiver (15), a first refrigerant mass partial flow is relaxed in the refrigerant valve with expansion function (14) and absorbs heat in the ambient heat exchanger (4), subsequently is guided to the refrigerant collector (11) via the shut-off valve (17) in bypass to the first 3 / 2-way refrigerant valve (8) and a second refrigerant mass partial flow is relaxed in the refrigerant valve with expansion function (5) and evaporates in the evaporator (6) with heat absorption from the air and is conducted to the compressor (1).14.The method for operating a refrigeration system and heat pump arrangement according to any one of claims 1 to 6 for reheat mode of the vehicle cabin in heat pump operation and using vehicle waste heat at ambient temperatures of more than 0°C, characterised in that the refrigerant, downstream of the compressor (1), emits heat in the heating condenser (2) or in the water-cooled condenser (18), subsequently is conducted via the second 3 / 2-way refrigerant valve (3) and the receiver (15) and, downstream of the receiver (15), a first refrigerant mass partial flow is conducted to the refrigerant valve with expansion function (5) and relaxed and evaporates in the evaporator (6) with heat absorption from the air and a second refrigerant mass partial flow, downstream of the receiver (15), is relaxed in the refrigerant valve with expansion function (10) and absorbs heat in the chiller (9) and subsequently is conducted to the compressor (1) via the refrigerant collector (11).15.The method for operating a refrigeration system and heat pump arrangement according to any one of claims 1 to 6 for reheat mode of the vehicle cabin in heat pump operation and using ambient heat and vehicle waste heat at ambient temperatures of more than 0°C, characterised in that the refrigerant, downstream of the compressor (1), emits heat in the heating condenser (2) or in the water-cooled condenser (18), subsequently is conducted via the second 3 / 2-way refrigerant valve (3) and the receiver (15) and, downstream of the receiver (15), a first refrigerant mass partial flow is conducted to the refrigerant valve with expansion function (5) and relaxed and evaporates in the evaporator (6) with heat absorption from the air and a second refrigerant mass partial flow, downstream of the receiver (15), is relaxed in the refrigerant valve with expansion function (10) and absorbs heat in the chiller (9) and subsequently is conducted to the compressor (1) via the refrigerant collector (11) and a third refrigerant mass partial flow downstream of the receiver (15) is relaxed in the refrigerant valve with expansion function (10) and absorbs heat in the ambient heat exchanger (4) and subsequently is guided to the refrigerant collector (11) via the shut-off valve (17) in bypass to the first 3 / 2-way refrigerant valve (8) and is conducted to the compressor (1) via the refrigerant collector (11).16.The method for operating a refrigeration system and heat pump arrangement according to any one of claims 1 to 6 in heat pump operation and using ambient heat at ambient temperatures higher than -30°C, characterised in that the refrigerant, downstream of the compressor (1), emits heat in the heating condenser (2) or in the water-cooled condenser (18), subsequently is conducted via the second 3 / 2-way refrigerant valve (3) to the receiver (15) and, downstream of the receiver (15), is relaxed in the refrigerant valve with expansion function (14) and absorbs heat in the ambient heat exchanger (4) and subsequently is guided to the refrigerant collector (11) via the shut-off valve (17) in bypass to the first 3 / 2-way refrigerant valve (8) and is conducted to the compressor (1) via the refrigerant collector (11).17.The method for operating a refrigeration system and heat pump arrangement according to any one of claims 1 to 6 in heat pump operation and using vehicle waste heat at ambient temperatures higher than -30°C, characterised in that the refrigerant, downstream of the compressor (1), emits heat in the heating condenser (2) or in the water-cooled condenser (18), subsequently is conducted to the receiver (15) via the second 3 / 2-way refrigerant valve (3) and, downstream of the receiver (15), is relaxed in the refrigerant valve with expansion function (10), evaporated in the chiller (9) and conducted to the compressor (1) via the refrigerant collector (11).18.The method for operating a refrigeration system and heat pump arrangement according to any one of claims 1 to 6 in heat pump operation and using ambient heat and vehicle waste heat at ambient temperatures higher than -30°C, characterised in that the refrigerant, downstream of the compressor (1), emits heat in the heating condenser (2) or in the water-cooled condenser (18), subsequently is conducted to the receiver (15) via the second 3 / 2-way refrigerant valve (3) and, downstream of the receiver (15), a first refrigerant mass partial flow is relaxed in the refrigerant valve with expansion function (14) and absorbs heat in the ambient heat exchanger (4) and subsequently is guided to the refrigerant collector (11) via the shut-off valve (17) in bypass to the first 3 / 2-way refrigerant valve (8) and conducted to the compressor (1) via the refrigerant collector (11) and a second refrigerant mass partial flow is relaxed in the refrigerant valve with expansion function (10), evaporates in the chiller (9) and is conducted to the compressor (1) via the refrigerant collector (11).19.The method for operating a refrigeration system and heat pump arrangement according to any one of claims 1 to 6 in heat pump operation and using a hot gas circuit of the refrigerant at ambient temperatures higher than -30°C, characterised in that the refrigerant, downstream of the compressor (1), emits heat in the heating condenser (2) or in the water-cooled condenser (18), subsequently is conducted to the receiver (15) via the second 3 / 2-way refrigerant valve (3) and, downstream of the receiver (15), is guided to the refrigerant valve with expansion function (10) and relaxed, evaporates in the chiller (9) and is conducted to the compressor (1) via the refrigerant collector (11).20.The method for operating a refrigeration system and heat pump arrangement according to any one of claims 1 to 6 in de-icing operation at ambient temperatures higher than -30°C, characterised in that the refrigerant, downstream of the compressor (1), reaches the ambient heat exchanger (4) via the first 3 / 2-way refrigerant valve (8) and condenses, reaches the receiver (15) via the check valve (16), after which the refrigerant is conducted to the refrigerant valve with expansion function (10) and relaxed there and evaporates in the chiller (9) and cools a battery cooling circuit, after which the refrigerant is guided to the suction side of the compressor (1) via the refrigerant collector (11).

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